Dispenser and Process

ABSTRACT

A dispenser ( 10 ) for dispensing flowable materials has a container ( 12 ) having an outer wall ( 16 ) and a membrane ( 34 ) collectively defining a first chamber ( 18 ) configured to contain a flowable material. The membrane ( 34 ) extends from the outer wall ( 16 ) at an angle. The membrane ( 34 ) has a thickness and a weld seam ( 40 ), and the weld seam ( 40 ) has a thickness less than the thickness of the membrane ( 34 ).

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation application of and claimspriority to U.S. patent application Ser. No. 12/362,062, whichapplication claims the benefit of and is a continuation-in-part of U.S.Patent Application No. 61/024,386, which applications are incorporatedby reference herein and made a part hereof.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

None.

TECHNICAL FIELD

The invention relates generally to a dispenser for a flowable materialor substance and more particularly, to a dispenser having a membranehaving enhanced rupturing characteristics for allowing a flowablesubstance to be contained and dispensed as desired.

BACKGROUND OF THE INVENTION

Containers capable of dispensing contents stored in the containers areknown in the art. In certain applications, a dispenser may have amembrane that is selectively rupturable wherein upon rupture, a flowablesubstance can be dispensed from the container. For example, U.S. Pat.Nos. 5,490,746 and 5,664,705 disclose containers having rupturablemembranes. The disclosed membranes, however, are made rupturable viascore lines in the membranes. As are known in the art, score lines areweakened areas, typically formed, by the removal of material. Themembranes are ruptured by creating hydraulic pressure within thecontainer where the membranes rupture along the score lines.Furthermore, in the membrane disclosed in U.S. Pat. No. 5,664,705,portions of the membrane overlap one another and the membrane is notintegral with the dispenser but rather separately affixed to thedispenser wall. The use of score lines provides less control over themanner in which the membrane will rupture. In addition, separatelyattaching a membrane to a container adds to the complexity of themanufacturing process and cost. In other embodiments, the membrane maybe generally flat or planar and have a weld seam that provides for therupturability of the membrane. Limitations in the structuralconfiguration of the prior art rupturable membranes can restrict theoperability of the membrane and the type of flowable substances that canbe suitably contained and dispensed from the container.

While such containers according to the prior art, provide a number ofadvantageous features, they nevertheless have certain limitations. Thepresent invention is provided to overcome certain of these limitationsand other drawbacks of the prior art, and to provide new features notheretofore available. A full discussion of the features and advantagesof the present invention is deferred to the following detaileddescription, which proceeds with reference to the accompanying drawings.

SUMMARY OF THE INVENTION

The present invention provides a dispenser having a membrane havingenhanced rupturing characteristics for dispensing flowable materials.

According to a first aspect of the invention, a dispenser is providedfor dispensing flowable material. The dispenser has a container havingan outer wall and a membrane collectively defining a chamber configuredto contain a flowable material. The membrane extends from the outer wallat an angle. The membrane has a thickness and a weld seam. The weld seamhas a thickness less than the thickness of the membrane.

According to another aspect of the invention, the membrane is generallyconically-shaped. In one exemplary embodiment, the membrane has aperipheral edge and an apex spaced from the peripheral edge. Theperipheral edge is integral with the outer wall.

According to another aspect of the invention, the angle the membraneextends from the outer wall is in the range from approximately 19° to25°. In a further exemplary embodiment, the angle is in the range fromapproximately 20° to 22.5°. In still a further exemplary embodiment, theangle is approximately 22.5°. These angles may be referred to as coneangles.

According to another aspect of the invention, the weld seam has athickness in the range of approximately 0.003 inches to 0.004 inches. Inan exemplary embodiment, the weld seam has a thickness of approximately0.0035 inches. In other exemplary embodiments, the weld seam has athickness of approximately 0.006 inches.

According to a further aspect of the invention, the membrane convergesto an apex and has a plurality of weld seams converging to the apex.

According to a further aspect of the invention, the outer wall has afirst extension member thereon proximate the membrane. The outer wallfurther has a second extension member thereon proximate the membrane andgenerally opposite the first extension member.

According to yet another aspect of the invention, the dispenser isformed by an injection-molding process. In one exemplary embodiment, thedispenser is formed of various thermoplastic materials and variouscombinations thereof.

According to another aspect of the invention, a membrane has a web ofmaterial that is generally conically-shaped. The web has a thickness anda weld seam wherein the weld seam has a thickness less than thethickness of the web.

According to other aspects of the invention, methods of dispensing aredisclosed using the dispenser as well as a method of forming thedispenser.

According to a further aspect of the invention, the dispenser has aconically-shaped membrane positioned at a proximal end of the dispenser.The membrane is fully exposed to an outside environment.

According to another aspect of the invention, a container assembly isprovided wherein a first container is positioned within a secondcontainer. Each container may have an angled or conically-shapedmembrane. The membranes are ruptured wherein flowable substancescontained within the containers mix to form a mixture. The mixture canthen be dispensed from the container assembly.

According to a further aspect of the invention, the dispenser may havemultiple chambers and multiple conically-shaped membranes.

Other features and advantages of the invention will be apparent from thefollowing specification taken in conjunction with the followingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

To understand the present invention, it will now be described by way ofexample, with reference to the accompanying drawings in which:

FIG. 1 is a perspective view of a dispenser according to the presentinvention;

FIG. 2 is a top plan view of the dispenser of FIG. 1 prior to sealing adistal end of the dispenser;

FIG. 3 is a cross-sectional view of the dispenser taken along lines 3-3in FIG. 2;

FIG. 4 is an enlarged partial cross-sectional view of a membrane takenof the area indicated in FIG. 3;

FIG. 4 a is another enlarged partial cross-sectional view of themembrane of the present invention;

FIG. 5 is another enlarged partial cross-sectional view of the membrane;

FIG. 6 is an end view of the membrane of the dispenser;

FIG. 7 is a cross-sectional view of a mold line or weld seam shown inFIG. 6;

FIG. 8 is a schematic end view of an alternative embodiment of thedispenser of the present invention;

FIG. 9 is an end view of the membrane having forces applied theretowherein the membrane is fractured along mold lines or weld seams;

FIG. 10 is a partial elevation view of the dispenser supporting a swabassembly;

FIG. 11 is a partial elevation view of the dispenser supporting adropper assembly;

FIG. 12 is a partial elevation view of the dispenser supporting a brushassembly;

FIG. 13 is a partial elevation view of the dispenser supporting a rollerassembly;

FIG. 14 is a perspective view of a core pin having an end face with araised structure;

FIG. 15 is a schematic cross-sectional view of a mold and a portion ofthe material for forming the dispenser;

FIG. 16 a-16 f are a series of views showing the injection moldingprocess of the membrane wherein adjacent mold segments abut to form moldlines or weld seams;

FIG. 17 is a schematic view of the dispenser being filled with aflowable substance or flowable material by a filling apparatus;

FIG. 18 is a partial schematic view of a sealing apparatus for sealing adistal end of the dispenser to contain the flowable substance;

FIG. 19 is a cross-sectional view of the dispenser of the presentinvention holding a flowable substance;

FIG. 20 is a cross-sectional view of the dispenser of the presentinvention showing a user rupturing the membrane of the dispenser;

FIG. 21 is a partial cross-sectional view of an alternative embodimentof the dispenser;

FIG. 22 is a perspective view of another embodiment of a dispenseraccording to the present invention;

FIG. 23 is an, end view of the dispenser of FIG. 22;

FIG. 24 is a cross-sectional view of the dispenser taken along lines24-24 in FIG. 23;

FIG. 25 is a cross-sectional view of the dispenser of FIG. 23 andshowing a user rupturing the membrane of the dispenser;

FIG. 26 is en end view of the ruptured dispenser of FIG. 25;

FIG. 27 is a cross-sectional view of another embodiment of the dispenserof the present invention;

FIG. 28 is a cross-sectional view of another embodiment of the dispenserof the present invention; and

FIG. 29 is a cross-sectional view of another embodiment of the dispenserof the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

While this invention is susceptible of embodiments in many differentforms, there are shown in the drawings and will herein be described indetail preferred embodiments of the invention with the understandingthat the present disclosure is to be considered as an exemplification ofthe principles of the invention and is not intended to limit the broadaspect of the invention to the embodiments illustrated.

Referring to the drawings, FIG. 1 discloses a dispenser according to thepresent invention generally designated by the reference numeral 10.FIGS. 2 and 3 show a container assembly 12 or container 12 prior tohaving one end sealed as will be described in greater detail below. Asshown in FIGS. 2 and 3, the dispenser 10 generally comprises a container12 with an elongated, longitudinal axis L having a peripheral wall 16,or outer wall 16. In one preferred embodiment, the container assembly 12is cylindrical. However, the container assembly 12 can be molded innumerous shapes, including an elliptical shape, rectangular shape orother various cross-sectional shapes. As will be described in greaterdetail below, in one exemplary embodiment, the dispenser 10 is generallyan integral, one-piece structure formed by an injection-molding process.It is understood that the length of the container 12 can vary dependinggenerally on the desired volume capacity.

As further shown in FIGS. 2 and 3, the container assembly 12 generallycomprises the outer wall 16 and a web 34 or membrane 34. The outer wall16 and the membrane 34 are preferably integral. As explained in greaterdetail below, the outer wall 16 and the membrane 34 are operablyconnected to cooperatively define a chamber 18. As will be explained,the container assembly 12 of the dispenser 10 can have a single chamber18 or multiple chambers can also be defined within the containerassembly 12.

As further shown in the exemplary embodiment of FIG. 3, the membrane 34is positioned along the longitudinal axis L between a proximal end 24and distal end 26 to define the first chamber 18 between the membrane 34and the distal end 26. A second chamber 20 is also defined between themembrane 34 and the proximal end 24, and may also be referred to as amixing chamber 42. The outer wall 16 is sealed together at the distalend 26 by any number of known sealing methods, including heat oradhesive sealing (See FIG. 18). Alternatively, the distal end 26 canreceive a cap to close the first chamber 18. When the distal end 26 issealed, and in cooperation with the membrane 34, the first chamber 18 isa closed chamber for holding a flowable material or flowable substance.As also shown in FIG. 3, the container 10 can be necked down wherein thesecond chamber 20 and, if desired, a portion of the first chamber 18 canhave a smaller diameter than the majority of the first chamber 18.Alternatively, the container 10 can have a constant diameter along itslongitudinal axis L.

In one exemplary embodiment, the membrane 34 can be formed extendingfrom the outer wall 16 at an angle. In particular, the membrane can bein a conical or spherical shape. As explained in greater detail below,this configuration provides certain unexpected results and benefits. Inthe disclosed configuration, the membrane 34 extends from the outer wall16 of the container 10 at an angle, which may be referred to as a coneangle. The angle of the membrane may also be considered from a straightor vertical axis. The membrane 34 is formed in a configuration that isgenerally not flat or planar. As depicted in FIGS. 3 and 4, the membrane34 is formed with abutting mold segments 60, 62. The membrane 34 mayhave a membrane thickness t₁. As explained in greater detail below, themold segments 60, 62 are formed together that abut to form a weld seam40, with a thickness t₂ (shown in FIG. 5). The thickness t₂ may beincreased over prior designs and can be set at approximately 0.006inches or be set at a traditional 0.003 to 0.004 inches but wherein suchthickness requires less force for rupture as explained in greater detailbelow. The mold segments 60, 62 are formed at an angle A as shown inFIGS. 3 and 4. Testing including finite element analysis has shown thatthe angle A can be at various angle ranges and in certain exemplaryembodiments, the angle A is 20° or 22.5° as shown measured in FIG. 4.The angle can be measured from a vertical axis passing through an end orapex of the membrane. This angle is also the angle that the membrane 34extends forward from the outer wall 16 of the dispenser 10. Other rangesare also possible such as between 20° to 25° or 5° to 40°. Broaderranges are also possible. Thus, the overall shape of the membrane 34 maybe considered conical in one exemplary embodiment rather than generallyflat, planar or straight as in prior designs. Described somewhatdifferently, the membrane has a peripheral edge 42 and an apex 44. Theapex 44 is spaced from the peripheral edge 42. Thus, the peripheral edge42 of the membrane 34, which is integral with the outer wall 16 in anexemplary embodiment, is positioned at one location along thelongitudinal axis L of the container 12 while the apex 44 is positionedat another location along the longitudinal axis L of the container, thusspaced linearly away from the peripheral edge 42. The mold segments 60,62, or membrane sections, extend from the peripheral edge 42 andconverge to the apex 44. It is also understood that the membrane 34 canbe angled but wherein the membrane segments do not converge to an apex.The apex could also be positioned at a location other than a generalcenter of the membrane if desired. In an exemplary embodiment, the apex44 is positioned at a center of the membrane 34. Alternatively, themembrane 34 can have a curvilinear shape such as a dome shape (notshown).

As further shown in FIG. 6, the membrane 34 contains a plurality ofrupturable members in the form of weld seams 40, which can be arrangedin a number of configurations including but not limited to a cross,star, or asterisk. It is understood, further, that the benefits of theinvention can be realized with a single weld seam 40 in the membrane 34.In a preferred embodiment, the weld, seams 40 are collectively arrangedin a plus-shaped configuration wherein the membrane generally has apie-shape. As shown in FIGS. 5 and 7, adjacent mold segments 60, 62 froman injection molding process abut with one another to form the weldseams 40. Due to the configuration of the mold to be described below,the weld seams 40 are formed to have a lesser thickness t₂ than themembrane thickness t₁. As further shown in FIG. 6, the plurality of weldseams 40 extend radially from substantially a center of the membrane 34(which may correspond to the apex 44) on the membrane 34 completely toan outer edge or the peripheral edge 42 of the membrane 34, and to theinterior surface of the container 12. It is understood, however, thatthe weld seams 40 do not need to extend to the peripheral edge 42 of themembrane 34. While a membrane containing weld seams 40 is preferred, itis understood that the rupturable members can take other forms tootherwise form a weakened member. Weakened members can take variousforms including frangible members, thinned members, or members formed byother processes, such as scoring.

The membrane 34 is similar to the membrane structure disclosed in U.S.Pat. No. 6,641,319, which is incorporated herein by reference. In a mostpreferred embodiment, the membrane 34 has four mold segments and whereinthe weld seams 40 generally form a cross or + shape. As shown in FIG. 16a, the process is controlled such that the adjacent mold segments 60, 62each meet at the separate interface areas 64. Each weld seam 40 has athickness less than the thicknesses of the segments 60, 62. Thethicknesses of the mold segments 60, 62 are considered to be themembrane thickness t₁ and the weld seams 40 are referred to with thethickness t₂ (FIGS. 5 and 7). It is understood that the membrane 34having the weld seams 40 is formed in the conical or tapered shape asshown in FIGS. 3 and 4.

Compression of the container 12 proximate the membrane 34, such as byfinger pressure, causes the membrane 34 to break, rupture, or fractureonly along the radial depressions or weld seams 40 forming a series offinger-like projections 39 which are displaced from one another (FIG. 9)and upon sufficient force can be in overlapping fashion to createmembrane openings 41 for release of the material from the first chamber18 into the second chamber 20, which may also be referred to as a mixingchamber 20. Because of the structure of the weld, seams 40, squeezingthe container 12 towards the distal end to create hydraulic pressureagainst the membrane 34 will not break or rupture the weld seams 40.Since the projections 39 are “pie-shaped” and widest at their outeredges 37, the center section of the web 34 breaks open the widest. Theamount of material that can be dispensed through the web 34 iscontrolled by the degree of the opening 41. The size of the opening 41is controlled by the configuration of the weld seams 40 and the pressureof the fingers of the user pressing on the container assembly 12 toassert pressure on the web 34. Rupturing of the membrane 34 will bedescribed in greater detail below. The resiliency of the material of thedispenser 10 allows the membrane 34 to return substantially to a closedposition when force is removed from the dispenser 10. The angledconfiguration of the membrane 34 provides a rupturing force to be lessthan prior designs. This provides certain advantages as described ingreater detail below.

As further shown in FIGS. 3-7, the web 34, or membrane 34, partitionsthe container assembly 12 to separate the first chamber 18 from thesecond chamber 20 or mixing chamber 20. Although FIG. 3 shows themembrane 34 closer to the proximal end 24 than the distal end 26, theplacement of the membrane 34 is a function of the desired volumecapacity of the respective chambers. As such, the membrane 34 could belocated at numerous locations in the container assembly 12. In oneembodiment, the membrane 34 could be positioned at an end of thedispenser 10 whereby the second chamber 20 or mixing chamber 42 iseliminated. Such an embodiment will be described in greater detailbelow.

As shown in FIGS. 3 and 4, the membrane 34 has a first surface 36 and asecond surface 38. The first surface 36 faces towards the first chamber18, while the second surface 38 faces towards with the second chamber20. The second surface 38 is angled but has a generally smooth surface.The first surface 36, however, has a plurality of bands or depressionsthereon formed by the weld seams 40. As will be described in greaterdetail below, and as generally shown in FIGS. 5-6, and 14-16, a firstsegment 60 of injected molded material abuts a second segment 62 ofinjected molded material to form the weld seam 40. As can be furtherseen in FIG. 5, the membrane 34 has a base thickness “t₁” between thefirst membrane surface 36 and the second membrane surface 38. Thethickness t₁ is generally referred to as the membrane thickness. Theweld seam 40 has a thickness t₂ that is less than the membrane thicknesst₁. This facilitates rupture of the membrane 34 as described below. Thefirst mold segment 60 and the second mold segment 62 abut to form theweld seam 40. During the molding process, the mold segments 60, 62 movetoward the interface area 64 in the directions of arrows B (FIG. 5).Furthermore, the mold segments 60, 62 meet substantially at theinterface area 64 at the lesser thickness t₂. This forms the weld seam40 at the lesser thickness facilitating rupture of the membrane 34. Ifthe mold segments 60, 62 did not meet at the interface area 64 but, forexample, substantially further to either side of the interface area 64,the weld seam 40 would be too thick and would not be able to rupture.Whichever mold segment 60, 62 moved past the interface area 64, thesegment would merely flex and not rupture as desired. Thus, as describedbelow, the molding process is controlled to insure that the moldsegments 60, 62 abut substantially at the interface area 64 to form theweld seam 40 having a thickness t₂ less than the membrane thickness t₁.With the angled membrane 34, the thickness t₂ can be increased overprevious designs while still providing for easy selective rupture by auser as discussed further below.

Explained somewhat differently, the first surface 36 of the membrane 34has a channel 66 formed therein (FIG. 7). The weld seam 40 confronts thechannel 66. The channel 66 is formed by a first wall 68 adjoining asecond wall 70. In a preferred embodiment, the first wall 68 adjoins thesecond wall 70 at substantially a 90 degree angle. Acute angles orobtuse angles are also possible. Thus, in one preferred embodiment, thechannels are V-shaped.

In another preferred embodiment, the membrane 34 forms four narrowspokes of substantially uniform width extending from substantially thecenter of the membrane 34 to the interior surface of the containerassembly 12, or towards the inner surface of the outer wall 16. Eachspoke extends at a certain angle from the adjacent spokes on eitherside. In other embodiments, the number of spokes can be increased ordecreased as desired.

As shown in FIGS. 1-2, the exterior surface 28 of the container assembly12 has an exterior extension 46 to indicate the exact location whereforce should be applied to rupture the membrane 34. The exteriorextension 46 is generally positioned proximate the membrane 34.Specifically, the extension 46 is located directly adjacent to themembrane 34. Although the extension 46 is shown as a thumb pad with aplurality of ridges 47, any type of raised area or projection includinga button, prong or ring will suffice. In another embodiment, as depictedin FIG. 21, the tube can be outfitted with first and second fingerexterior extensions 46 to provide the user with further direction as towhere force should be applied to rupture the membrane 34. In addition, aring of material could be applied around the perimeter of the containerassembly 12 corresponding to the location of the web 34 so that a userwould know precisely where to apply finger pressure. Any indicia-bearingmarking would also be sufficient. Additional exterior extensions 46 canbe used if desired. The exterior extensions 46 or other indicia couldalso be eliminated from the design if desired.

As shown in FIGS. 3 and 4, the interior surface 28 of the second chamber20, which may also be considered a dispensing chamber, may include ribs48. In one preferred embodiment, the ribs 48 may take the form ofcircumferential ribs 48. As shown in an alternative embodiment of FIG.8, the interior surface 28 of the dispensing chamber 42 has a pluralityof longitudinal ribs 48 that extend longitudinally along the interiorsurface 28. The ribs 48 are thus oriented axially in the dispensingchamber 42 and can be of varying length. The ribs 48 could be shortenedand extend radially inwardly. The ribs 48 secure different applicators44, such as a swab 49 (FIG. 10) or dropper 50 (FIG. 11), a brush 51assembly (FIG. 12), or a roller 53 assembly (FIG. 13) which can be usedto apply the dispensed liquid or solid flowable material. The differentapplicators may form an interference fit with the ribs 48. The differentapplicators 44 are in communication with the second chamber 20 ordispensing chamber 20 as shown in FIGS. 10-13.

As further shown in FIG. 10 the swab 49 engages the inner surface 28 ofthe dispensing chamber. Once the membrane 34 is fractured as described,the swab 49 receives and absorbs the material M as it is dispensed fromthe first chamber 18 and enters the dispensing chamber 20. The swab 49has a contact surface that is used to dab a desired area such as a skinsurface having an insect bite. The dispenser 10 can be inverted andsqueezed until the swab 49 surface is wet. The dispenser 10 can then beheld in a vertical position with the swab 49 pointed upwardly.Alternatively, the swab 49 can be made of a material of relatively largeporosity for passing droplets through the swab 49 by gravity and fordispensing droplets from its exterior surface. The swab 49 can be madeof polyester, laminated foamed plastic, cotton or the like.

FIG. 11 shows the dispenser 10 having a dropper attachment 50. Thesecond chamber 20 has a dropper 50 attached thereto. The dropper 50 hasan elongated spout 52 with a passageway 54 for dispensing droplets ofthe material. The dropper 50 has a cup-like portion 56 that overlaps aportion of the outer surface of the second chamber 20. Once the membrane34 is ruptured as described and material passes from the first chamber18 to the dispensing chamber 20, droplets of the material can bedispensed through the spout 52. The dispenser 10 can be similarlymanipulated to dispense the flowable material using the differentapplicators of FIGS. 11-13.

In a preferred embodiment, the dispenser 10 is made of thermoplasticmaterial. The material could be transparent, translucent or opaque. Thepreferred plastic material is polyethylene or polypropylene but a numberof other plastic materials can be used. For example, low-densitypolyethylene, polyvinyl chloride or nylon copolymers can be used. In apreferred embodiment, a mixture of polypropylene and polyethylenecopolymer or thermoplastic olefin elastomer is used. In anotherpreferred embodiment, a mixture of polypropylene and Flexomer®,available from Dow Chemical, is utilized. In addition, low densitypolyethylene with linear low density polyethylene can be used. It isessential that the dispenser be made of material which is flexibleenough to allow sufficient force to rupture the membrane 34. Also, in apreferred embodiment, the dispenser is a one-piece integrally moldedmember. Due to the enhanced features of the conical membrane 34,additional blends of polyethylene and polypropylene can be used thatcould not previously be used due to limitations such as in the moldingcapabilities of the materials in forming the dispenser or rupturabilityof the weld seams once the membrane is formed. For example, blends withan increased amount of polypropylene can be used with the angled orconical membrane as the membrane can be readily ruptured, and suchblends further provide increased chemical resistant properties. Withincreased chemical resistance, the dispenser can be used to contain awider variety of flowable substances. In prior designs utilizing suchpercentages of polypropylene, the membrane was not capable of beingruptured via finger pressure. A dispenser made solely of nylon is alsopossible.

The preferred dispenser 10 has a length of about 1.5 to about 3.0inches, although larger containers can be utilized, with 2 to about 2.5inches being preferred. The outside diameter of the container assemblyis about 0.30 to about 1.0 inches.

The exterior extension 46 is preferably about 0.10 to about 0.50 inchesin width and about 0.010 to 0.125 inches thick. The second chamber 20 ispreferably about 0.20 to about 1.5 inches and preferably 0.75 inches inlength. The membrane 34 preferably has a thickness of about 0.02 toabout 0.0625 inches. The weld seams 40 have a preferable thickness ofabout 0.003 to about 0.008 inches and preferably about 0.003 to 0.004inches. In another exemplary embodiment, the weld seam 40 thickness maybe 0.006 inches. The above dimensions can be varied depending uponoverall dispenser size.

The method of making the dispenser 10 is generally illustrated in FIGS.14-16 and is similar to the process described in U.S. Pat. No.6,641,319. The dispenser 10 is preferably produced in a single moldingoperation thus providing a one-piece injected-molded part. As shown inFIG. 15, a mold 80 is provided having a mold cavity 82 therein. The moldcavity 82 is dimensioned to correspond to the exterior surface of thedispenser 10. A first core pin 84 and a second core pin 86 are provided.The core pin 84 is dimensioned to correspond to the interior surface ofthe dispenser 10. It is understood that the core pin could have ashoulder to form the tapered portion, or necked-down portion of thedispenser 10. Alternatively, the core pin could have a constant diameterif there is to be no tapered portion (different core pin options areshown in FIGS. 14-15).

As shown in FIGS. 14 and 15, the first core pin 84 has an end face 88that is angled or conically-shaped. The end face 88 also has raisedstructures 90 thereon. The second core pin 86 has an end face 100 thatis generally recessed. The raised structures 90 on the first core pin 84are in the form of a ridge 92. The ridge 92 is what provides for thedepressions or weld seams 40 at the certain thickness in the membrane34. In a preferred embodiment, the ridge has a first wall 94 adjoining asecond wall 96 to form a line 98.

Furthermore, in a preferred embodiment, the ridge 92 comprises aplurality of ridges radially extending substantially from a center pointof the end face 88. The ridges 92 define a plurality of membranesegments, or mold gaps 93, between the ridges 92. Thus, it can beunderstood that the raised structure 90 in the form of the ridges 92provides the corresponding structure of the membrane 34. Although shownas triangular, the ridges 92 can be formed in a number of shapes. Inaddition, the ridges 92 can be arrayed in a multitude of shapes,including a single line, a cross, a star, or an asterisk. Varying theshape of the ridges 92 will affect the shape of the channels 66 in themembrane 34.

The first core pin 84 is inserted into the mold 80 with the raisedstructure 90 facing into the mold cavity 82. A first space 104 ismaintained between the mold 80 and the length of the first core pin 84.The second core pin 86 is also inserted into the mold cavity 82 whereina second space 106 is maintained between the mold 80 and the second corepin 86. The core pins 84, 86 are generally axially aligned wherein theend face 88 of the first core pin 84 confronts the end face 100 of thesecond core pin 86 in spaced relation. Thus, a membrane space 108 isdefined between the respective end faces 88 and 100 of the core pins 84and 86. End plates 110, 112 are installed on end portions of the mold 80to completely close the mold. An exterior extension cavity 117 islocated on the surface of the mold 80 and adjacent to a membrane space108.

As shown in FIG. 15, molten thermoplastic material is injected into themold cavity 82 through an inlet 114. The material flows into the firstspace 104, second space 106, and membrane space 108. The plasticinjection is controlled such that the plastic enters the membrane space108 simultaneously in the circumferential direction. The raisedstructures 90 separate the material into separate mold segments 60, 62that flow into the mold gaps. As shown in FIGS. 15 and 16, the moldsegments 60, 62 flow first into the wider portions of the mold gaps 93as this is the area of least resistance. The material continues to flowinto the membrane space 108 and then the adjacent mold segments 60, 62abut at the interface area 64 to form the weld seams 40. As can beappreciated from FIG. 15, the weld seams 40 have a lesser thickness thanthe membrane thickness. The mold segments 60, 62 meet and abut at theinterface area 64 to form the weld seam 40. It is understood that themembrane space 108 is angled thus forming the angled membrane 34. Duringthis process, air is vented from the mold cavity 82 as is conventional.

Once the plastic injection is complete, the material is allowed to cool.A cold water cooling system 116 could be utilized wherein cold water ispumped into the mold 80 outside of the cavity 82 if desired. Oncecooled, the dispenser 10 can be removed from the mold 80.

As shown in FIG. 17, the dispenser 10 can be passed on to a fillingapparatus 120. The dispenser 10 is then filled with flowable material.As shown in FIG. 18, the distal end 26 of the dispenser 10 is sealed byheat sealing dies 198. The excess end portion can then be cut-off anddiscarded. It is understood that heat sealing is one preferred sealwhile other sealing methods could also be utilized.

Thus, a one-piece injection molded dispenser is provided. The one-piececonstruction provides a more repeatable part and at greatermanufacturing efficiency than providing a separate piece that is securedinto a container assembly. If desired, however, the membrane 34 could beseparately molded and affixed into a container assembly 12. A one-piecemolding process, however, is preferred. In addition, because themembrane 34 is molded to have the weld seams, radial depressions, orbands, an additional manufacturing step such as scoring to create aweakened rupturable member is unnecessary. This allows the manufactureof dispensers having relatively small diameters since there is no needto allow sufficient clearance for a scoring tool. In such smallconfigurations, it is difficult to control the scoring operation. Byforming the depressions by injection molding, the desired thicknessescan be closely controlled. The membrane 34 also resists rupture fromhydraulic pressure while being easily rupturable when forces are appliedto the membrane. Also, the construction of the membrane 34 allows forthe precise control of material to be dispensed by controlling theamount of force on the membrane 34. It is further understood that thedepressions or channels could be formed on both sides of the membrane 34if desired. In such configuration, however, the ability of the membraneto also function as a check valve is lessened. In a preferredembodiment, however, the membrane has the depressions molded on only oneside. It is further understood while certain dimensions are preferredfor certain embodiments, dispensers of all sizes having similar relativedimensions can be formed according to the present invention. It is alsounderstood that in certain embodiments of the multi-chambered dispenser,the rupturable member could be other than a weld seam if desired. Forexample, a scored line could be provided, a frangible seam, or otherrupturable member.

FIGS. 19-20 disclose operation of the dispenser 10 after being filledand sealed as shown in FIGS. 17 and 18. In operation, a user applies aselective force F on the dispenser 10 at the exterior extension 46adjacent to the membrane 34. When sufficient force F is applied, asshown in FIG. 20, lateral pressure is applied to the membrane 34 causingthe membrane 34 to shear, rupture or fracture along the weld seams 40.The membrane 34 ruptures only along the weld seams 40 to create themembrane openings 41. The angled membrane 34 provides a distinct audible“popping” sound when rupturing. It has further been found that theangled membrane 34 with the weld seam 40 provides a more distinctaudible sound. Upon rupture of the membrane 34, material passes from thefirst chamber 18 through the membrane 34 and into the second chamber 20or dispensing chamber 20. The material flow rate through the membrane 34and into the dispensing chamber 20 is controlled by the degree ofmembrane opening which is directly related to the amount of force Fapplied to the membrane 34 by the user. Therefore, the user canprecisely regulate the flow of material after rupture of the membrane34. In addition, the membrane 34 can preferably have elasticcharacteristics wherein when force F is removed, the membrane 34 returnssubstantially to its original position. While the weld seams 40 may beruptured, the segments 60, 62 can form a close enough fit to preventmaterial from flowing past the membrane 34 without additional pressureon the material. Thus, the membrane 34 can act as a check valve toprevent unwanted flow of the material back into the first chamber 18.

As explained in greater below, the present design unexpectedly yielded adesign that would rupture upon the application of force F, wherein theforce F was less than the force required to rupture the membranedisclosed in the '319 patent discussed above. This provides additionaloptions for the dispenser 10 such as a membrane that is more easilyrupturable or a membrane that has a thickened weld seam 40 but thatstill allows easy rupture via finger pressure as shown in FIG. 20.Additional material options also become possible with the conicalmembrane 34.

FIG. 21 discloses another embodiment of the dispenser 10 of the presentinvention. It is understood that the dispenser shown in FIG. 21 has anangled membrane 34 as described above. The dispenser 10 has a firstexterior extension 46 and a second exterior extension 46. The pair ofexterior extensions 46 are positioned generally in opposed relation atopposite ends of the membrane 34. As discussed, the angled membrane 34provides for a lesser lateral force for rupturing the membrane 34. Thepair of exterior extensions 46 provide additional material proximate themembrane 34 to reduce the chances of an inadvertent rupture of themembrane 34. In operation, a user applies finger pressure at eachexterior extension 46 to rupture the membrane 34 consistent with thediscussion above.

FIGS. 22-26 disclose another embodiment of the dispenser of the presentinvention, generally designated with the reference numeral 210. Thisdispenser is similar in structure and operation to the dispenser 10 ofFIGS. 1-22. Differences will be discussed herein. The dispenser 210 hasa container 212 having an outer wall 218 and a membrane 234. Thesestructures cooperate to define a sealed chamber 218 therein forcontaining a flowable material. The membrane 234 is a conical membraneextending from the outer wall 216 at an angle. The membrane 234 furtherhas a plurality of weld seams 240 as discussed above. In an exemplaryembodiment, the cone angle is 22.5 degrees, although as discussed, otherangles are also possible. As shown in FIGS. 22 and 24-25, the membrane234 is positioned at a proximal end 224 of the dispenser 210 rather thanat an intermediate location along the outer wall 216. Thus, the conicalmembrane 234 is fully exposed on its outer side to any outsideenvironment. With this configuration, it is understood, that the second,chamber or dispensing chamber is eliminated. In operation, and as shownin FIGS. 25-26, force is applied proximate the conical membrane 234 atthe end of the dispenser 210 wherein the membrane 234 ruptures along theweld seam 240. This provides an opening in the membrane 234 whereinflowable materials contained therein can be dispensed from thedispenser. When the membrane ruptures, a distinct audible “pop” sound isproduced. Overall, the dispenser 210 is formed and operates as describedabove.

FIGS. 27-28 disclose additional embodiments of the present invention. Inthese embodiments, a tandem container is utilized wherein a firstcontainer is contained within a second container to form a containerassembly. As shown in FIG. 27, the first container is a dispenser suchas shown in FIGS. 22-26 described above and designated with thereference numeral 311. The dispenser 311 is sealed with a first flowablesubstance M1 and placed within a second container, such as the containerof FIGS. 1-22, generally designated with the reference numeral 310. Thesecond container 310 holds a second flowable substance M2. Thecontainers 310, 311 each have a conical membrane 334 having the benefitsdescribed herein. Upon operation, it is understood from the discussionabove that a user applies force to the second container 311 at the outerwall and proximate the conical membrane 334 of the first container 311thus rupturing the rupturable membrane 334 of the first container 311.The first, flowable substance M1 then passes by the membrane 334 andmixes with the second flowable material M2 to form a mixture. The userthen applies force to the second container 310 proximate its conicalmembrane 334 wherein the mixture can be dispensed from the containerassembly. FIG. 28 discloses a similar configuration but wherein thesecond container 310 has a generally straight membrane 334 a such asshown in the '319 patent. Operation of the container assembly isgenerally identical as that described regarding FIG. 27. It isunderstood that either of the first container 311 or the secondcontainer 310 can have a conical membrane. The containers 310, 311 mayalso be sealed together at their distal ends or the first container 311may be sealed separately and merely contained loosely within the chamberof the second container 310. It is further understood that thedesignations “first” and “second” are used for illustrative purposes.

As shown in FIG. 29, in an alternative embodiment, a dispenser orcontainer assembly is provided and designated with the reference numeral410. The dispenser has a dividing wall 419 that divides the chamber ofthe dispenser into multiple chambers, namely a first chamber 418 and asecond chamber 420. The first chamber 418 can be adapted to contain afirst flowable material M1 to be dispensed, and the second chamber 20can be adapted to contain a second flowable material M2 to be dispensed.A first angled membrane 434 a can be provided such that it encloses thefirst chamber 418, and a second angled membrane 434 b can be providedsuch that it encloses the second chamber 420 to prevent the flow ofmaterials M1 and M2 respectively. Both of the angled membranes 434 a,434 b operate similar to the membrane 34 discussed above. The membranes434 a, 434 b extend at angles from the outer wall similar as describedabove and the angles associated with the first angle membrane 434 a andthe second angled membrane 434 b can be the same. The first anglemembrane 434 a and the second angle membrane 434 b can be considered afirst membrane section and a second membrane section of an overallmembrane structure. Each membrane 434 a, 434 b can be separatelyruptured to control the flow of the individual flowable materials M1,M2. Additionally, in a further exemplary embodiment, a single angledmembrane can be used, to cover the first and second chambers 18, 20similar to membrane 34 discussed above. In such an embodiment, thedividing wall 19 would extend from proximate a mid-portion of themembrane 34. Upon rupture of the membranes, both M1 and M2 will flowfrom the first and second chambers 418, 420. A third chamber 442 can beused as a mixing chamber for the first flowable material M1 and thesecond flowable material M2.

The chamber dividing wall 419 is positioned in, between the firstchamber 418 and the second chamber 420 as shown in FIG. 29, and is apreferably planar member. The chamber dividing wall 419 has a sufficientthickness to divide and separate the chambers. The first and secondchambers 418, 420 can vary in length as desired. The chamber dividingwall 419 divides the first chamber 418 and the second chamber 420, andpreferably joins to the membrane 34 at the membrane center point thatdefines a non-rupturable member 433. Thus, the non-rupturable member 433may be considered connected to the dividing wall 419. While the dividingwall 419 extends substantially the entire longitudinal length of thecontainer, it is understood that the dividing wall 419 can extend pastthe outer wall 416 of the container. This extended portion can be usedby automation machinery used in the filling process of the dispenser 10.The dividing wall 419 divides the container assembly 412 evenly alongits longitudinal axis, making the first chamber 418 and the secondchamber 420 generally of equal size. This position of the dividing wall419 can vary to change the volumes of the chambers as desired. It isfurther contemplated that are other tandem container assemblies arepossible. For example, separate components can each having an angled orconical membrane and define a chamber for holding a flowable substance.After filling the chambers, the components can be sealed together toform a container assembly capable of separately storing multiplecomponents. The conical membranes can then be ruptured wherein theflowable substances can be mixed together to form a mixture anddispensed from the container assembly.

It is understood that the “first” and “second” designations for thedispenser of the present invention can be reversed as desired. It isfurther understood that the term “outer” when describing the outer wallof the dispenser is a relative term. It is understood that the dispenserof the present invention could be incorporated into other structuresthat may encompass the outer wall. The outer wall of the dispenser ofthe present invention, cooperates with the membrane and dividing wall incertain embodiments to define the chambers of the dispenser.

Forming the membrane 34 into an angled, conical or spherical shapeprovides certain advantages. Less force can be applied to the membrane34 in order to rupture the weld seam 40 thereby making it easier for auser to break the weld seam 40 to dispense the flowable substance in thedispenser 10. This can be useful in applications where users havedifficulty providing a greater rupturing force via finger pressure. Withless force required for rupture of the weld seam 40, the weld seam 40can also be molded having a thicker dimension t₂ if desired. With athicker dimension, the typical force required for rupturing the membranecan be maintained if desired. With a thicker dimension, vapor passage ofthe flowable substance through the weld seam 40 is minimized. Weld seams40 having minimal thicknesses are more susceptible to vapor passagetherethrough, which affects the expected concentration of the flowablesubstance contained in the container 10. This can also increase chancesof contamination. As the membrane thickness increases, more materialsare suitable for forming the membrane 34, thereby increasing theflexibility of uses for the container 10 as the container 10 can be usedwith more flowable substances. The angled membrane 34 also provides fora distinct audible “pop,” as it is ruptured. This is desirable such thatthe user then has a definitive indication that the weld seam 40 hasruptured.

The inventors note that the angled membrane disclosed herein was arrivedat after investigation and considerable testing and discovery. Whenconsidering membranes of other shapes, the inventors originally did notconsider that an angled or conical membrane would properly function. Itwas expected that such a design would not rupture and instead, merelyfold upon itself. To the contrary as explained herein, the angled orconical membrane provided unexpected results and enhanced benefits.

The rupturable membrane having a weld seam disclosed in U.S. Pat. No.6,641,319 (the '319 patent) provides significant advancement over theprior art. This rupturable membrane disclosed in the '319 patent isgenerally a planar membrane and positioned within the dispenser in astraight configuration wherein the membrane is generally transverse tothe outer wall of the dispenser. This design provides a membrane thatgenerally consistently ruptures upon the application of force (such asby fingers pressing at the membrane) proximate the membrane as discussedin the '319 patent. Over time, it was discovered that in rarecircumstances, certain users of the dispenser disclosed in the '319patent could not rupture the membrane. In such occurrences, the membranewould deflect but the weld seams tended to act similar to a living hingeand would not break. Upon further study of these rare occurrences, itwas found that users were at times applying force too slowly than whatmost users applied with general finger pressure. When applying forcemore slowly, the molecular structures of the weld seam had time torealign such that rupture along the weld seam would not occur. Althoughthese occurrences were rare, it prompted further study to determine ifother membrane shapes could provide additional solutions or rupture withthe application of more slowly-applied forces. Other membrane shapeswere considered including an angled type membrane and, in particular, aconical membrane.

In the course of the studies relating to the rupturable membrane of the'319 patent, it was already recognized that the weld seam, formed fromsegments of abutting plastic injection molded material, would rupturealong the weld seam when subjected to force proximate the weld seam.Also in the course of these studies, it was discovered that the weldseam of the membrane was subjected to tensile stresses when rupturing.This provided greater understanding of the rupturable membrane of the'319 patent. In view of this finding, when considering an angled orconical membrane, it was then considered that such a design may providean enhanced state for rupturing. This was contrary to originalconsiderations by the inventors herein that such a membrane would merelyfold upon itself and not rupture. Further investigation and testing ofan angled or conical membrane having a weld seam showed that themembrane did not fold upon itself but did indeed rupture along the weldseam. Upon further detailed testing, it was found that the conicalmembrane required less force to rupture the weld seam than the membranehaving a weld seam of the '319 patent. This provided additional optionsif a lesser rupture force was desired. This also allowed for thickeningthe weld seam and membrane to such that the weld seam in a conicalmembrane would rupture upon application of the same amount of force astypical with the membrane of the '319 patent. As a result, molding ofthe membrane can be made easier and less costly because the membrane andweld seam are thicker wherein broader tolerances are possible resultingin less rejected parts. In addition, vapor passage through the thickenedweld seam was decreased allowing for an increased number of flowablematerials that could be contained by a dispenser having such a membrane.As an example, one exemplary embodiment of a membrane of the '319 patentmay have a weld seam thickness of approximately 0.0035 inches. A weldseam of such a membrane design will rupture at approximately 8 psiapplied, for example, via finger pressure. This value was determined tobe a typically desirable force that most users could apply to themembrane. With a conical membrane having a weld seam of approximately0.0035 inches, detailed testing showed that the weld seam ruptured atapproximately 5.5 psi. Thus, a lower rupture value was achieved. Furthertesting then showed that the weld seam thickness in a conical membranecould be increased to approximately 0.006 inches and would rupture atapproximately 8 psi. Accordingly, the weld seam could be thickened. Suchresults also showed that a dispenser could be manufactured having alesser force required for rupture, e.g. 5.5 psi for a weld seamthickness of 0.0035 inches, such as for users having an arthriticcondition where it was more difficult to provide a suitable rupturingforce. Such findings also showed that a dispenser having a conicalmembrane and weld seam, could be made with additional blends ofpolyethylene and polypropylene as the weld seam would rupture and not betoo stiff thus resisting rupture. In prior designs, if the membranematerial was too stiff, the membrane was not suitably rupturable via thefingers of a user which was not practical.

Upon further study of the straight or planar membrane of the '319patent, it, was discovered that when force is applied proximate themembrane, the force must first overcome the buckling resistance of themembrane sections adjacent the weld seam, as the membrane sections aregenerally aligned with the direction of the force applied. Once theforce tends to buckle these sections, the weld seam is placed in tensionand upon sufficient application of further force, the weld seam rupturesproviding an opening in the membrane. Because of the shape of the angledor conical membrane of the present invention, the force appliedproximate the membrane is not generally aligned with the membranesections. Consequently, the force applied does not need to firstovercome the buckle resistance of the membrane sections. The force isgenerally immediately directed on the weld seam wherein the weld seam isplaced further in tension and ruptures. As a result, less force isrequired to rupture the angled or conical membrane than is required inthe membrane of the '319 patent. As discussed above, with less forcerequired to rupture the membrane, the membrane and weld seam could beconstructed in a thicker construction while still allowing rupture. Witha thicker weld seam, less vapor passage occurs through the weld seamimproving the performance of the dispenser container and allowing thecontainer to contain a wider variety of materials such thatconcentrations of the flowable materials are better maintained. Inaddition, other materials could now be used to form the membrane andcontainer. These materials included more chemically-resistant materialsthat further allowed an increase in the number of flowable materialsthat could be contained and dispensed from the container. Such an angledor conical membrane design further allows the dispenser to be made fromother thermoplastic engineering materials and combinations thereof. Suchmaterials include those that provide better chemical resistance and lessvapor and oxygen transmission that could not be used in prior designsbecause such materials are too stiff to rupture the membrane withtypical force provided by finger pressure. In one example, a blend ofmaterials can now be used that includes a greater percentage ofpolypropylene. While such a blend provides more stiffness, the conicalmembrane will still rupture via finger pressure. The increase amount ofpolypropylene also provides a dispenser have greater chemical resistantproperties. In another example, a dispenser having a conical membranecan be formed solely from nylon.

The dispenser of the present invention is designed to primarily containand dispense flowable materials that are fluids. Other flowablematerials can also be used. For example, the flowable material could bea liquid. Also, in other embodiments, the flowable materials M1, M2could both be fluids. In another embodiment, the first flowable materialM1 could be a liquid, and the second flowable material M2 could be apowder to be mixed with the fluid. Other combinations depending on theuse are also permissible. This permits the dispenser 10 to be used in awide variety of uses, and contain and dispense a large variety of fluidsand other flowable substances. The following is a non-exhaustivediscussion regarding the many possible uses for the dispenser of thepresent invention. It is understood that related uses to those describedbelow are also possible with the dispenser.

In one example, the dispenser of the present invention can be used in atwo-part hair care product such as a hair dye kit. A first flowablesubstance of the hair dye kit can be carried in the first chamber, and asecond flowable substance of the hair dye kit can be carried in thesecond chamber. The membrane is ruptured wherein the two flowablesubstances can be mixed together to form a mixture or solution. Themixture or solution can then be dispensed from the dispenser onto thehair of a user. In a multitude of other examples, the dispenser candispense a flowable material or mixture that is an adhesive, epoxy, orsealant, such as an epoxy adhesive, craft glue, non-medical super glueand medical super glue, leak sealant, shoe glue, ceramic epoxy, fishtank sealant, formica repair glue, tire repair patch adhesive, nut/boltlocker, screw tightener/gap filler, super glue remover or goo-b-gone.Also, the dispenser can dispense a flowable material or mixture that, isan automotive product, such as a rear view mirror repair kit, a vinylrepair kit, an auto paint touch up kit, a window replacement kit, ascent or air freshener, a windshield wiper blade cleaner, a lockde-icer, a lock lubricant, a liquid car wax, a rubbing compound, a paintscratch remover, a glass/mirror scratch remover, radiator stop-leak, ora penetrating oil. The dispenser can also dispense a flowable materialor mixture that is a chemistry material, such as a laboratory chemical,a fish tank treatment, a plant food, a cat litter deodorant, a buffersolution, a rehydration solution of bacteria, a biological stain, arooting hormone, a colorant dispenser, or disinfectants.

Moreover, the dispenser can dispense a flowable material or mixture thatis a cosmetic, fragrance or toiletry, such as nail polish, lip gloss,body cream, body gel, hand sanitizer, cologne, perfume, nail polishremover, liquid soaps, skin moisturizers, tooth whiteners, hotelsamples, mineral oils, toothpastes, or mouthwash. The dispenser can alsodispense a flowable material or mixture that is an electronics product,such as a cleaning compound, a telephone receiver sanitizer, a keyboardcleaner, a cassette recorder cleaner, audio/video disc cleaner, a mousecleaner, or a liquid electrical tape. In addition, the dispenser candispense a flowable material or mixture that is a food product, such asfood colorings, coffee flavorings, spices, food additives, drinkadditives, confections, cake gel, sprinkles, breath drops, condiments,sauces, liquors, alcohol mixes, energy drinks, or herbal teas anddrinks. The dispenser 10 can also dispense a flowable material ormixture that is a hair care product, such as hair bleaches, hairstreaking agent, hair highlighter, shampoos, hair colorants,conditioners, hair gels, mousse, hair removers, or eyebrow dye. Thedispenser can also dispense a flowable material that is a home repairproduct, such as a caulking compounds or materials, a scratch touch upkit, a stain remover, a furniture repair product, a wood glue, a patchlock, screw anchor, wood tone putty or porcelain touch-up.

In addition, the dispenser can dispense a flowable material or mixturethat is a test kit, such as a lead test kit, a drug kit, a radon testkit, a narcotic test kit, a swimming pool test kit (e.g., chlorine, pH,alkalinity etc.), a home water quality tester, a soil test kit, a gasleak detection fluid, or a pregnancy tester. The dispenser can dispensea large variety of lubricants including industrial lubricants, oils,greases, graphite lubricants or a dielectric grease. The dispenser canalso dispense a flowable material or mixture that as part of a medicaldevice test kit, such as a culture media, a drug monitoring system, amicrobiological reagent, a streptococcus test kit, or a residualdisinfectant tester. In addition, the dispenser 10 can dispense a largevariety of medicinal products, such as blister medicines, cold soretreatments, insect sting and bit relief products, skin cleaningcompounds, tissue markers, topical antimicrobials, topical demulcent,treatments for acne such as acne medications, umbilical areaantiseptics, cough medicines, waterless hand sanitizers, toothacheremedies, cold medicines and sublingual dosages. Furthermore, thedispenser can dispense a flowable material or mixture that is a noveltyproduct, such as a chemiluminescent light, a Christmas tree scent, aglitter gel, and a face paint. The dispenser can also dispense a varietyof paint products such as novelty paints, general paints, paintadditives, wood stain samples, caulk, paint mask fluid or paint remover.The dispenser can also dispense a flowable material or mixture that is apersonal care product, such as shaving cream or gel, aftershave lotion,skin conditioner, skin cream, skin moisturizer, petroleum jelly, insectrepellant, personal lubricant, ear drops, eye drops, nose drops, cornmedications, nail fungal medication, aging liquids, acne cream, contactlens cleaner, denture repair kit, finger nail repair kit, liquid soaps,sun screen, lip balm, tanning cream, self-tanning solutions orhomeopathic preparations. A large variety of pest control products canbe dispensed by the dispenser, including insect attractants, pesticides,pet medications, pet insect repellants, pet shampoos, pest sterilizers,insect repellants, lady bug attractant and fly trap attractant. Varioussafety products can be dispensed through the dispenser includingrespirator tests and eye wash solution.

The dispenser can also dispense a large variety of stationery or craftproducts, such as magic markers, glitter gels, glitter markers, glitterglues, gel markers, craft clues, fabric dyes, fabric paints, permanentmarkers, dry erase markers, dry eraser cleaner, glue sticks, rubbercement, typographic correction fluids, ink dispensers and refills, paintpens, counterfeit bill detection pen, envelope squeeze moisturizers,adhesive label removers, highlighters, and ink jet printer refills. Thedispenser can also dispense various vitamins, minerals, supplements andpet vitamins. The dispenser can also dispense a flowable material ormixture in a variety of other applications such as for aroma therapyproducts, breathalyzer tests, wildlife lures, eyeglass cleaners,portable lighting fuels, bingo and other game markers, float and sinkerdevices, toilet dyes and treatments, dye markers, microbiologicalreagents, shoe polishes, clothing stain removers, carpet cleaners andspot removers, tent repair kits, plumbing flux applicator, rust remover,tree wound treatment, animal medicine dispenser, animal measured fooddispenser, odor eliminator liquids, multi-purpose oils, ultrasoniccleaner concentrate, manufacturing parts assembly liquids and irrigationsolutions. In addition, the dispenser can be used as, or in connectionwith a suction device for culture sampling, taking various liquidsamples, taking various swabbing samples and for acting as a chemicaltester, such as may be used for testing drinks for various “date rape”drugs. In addition, the dispenser can dispense a variety of sportsproducts including sports eye black, football hand glue, and baseballglove conditioner and pine tar. The dispenser can dispense any varietyof flowable materials including liquids and powders, and furtherincluding a liquid and a powder, two or more powders, or two or moreliquids. The dispenser may be used as part of 2-part system (mix beforeuse) including a liquid with a powder, a liquid with a liquid, a powderwith a powder, or sealed inside another tube or product container orpartially sealed, connected or attached to another container. Thedispenser may also be used as part of a plunger dispensing system anddiagnostic testing.

The dispenser of the present invention may also be used for windshieldwiper blade cleaner and other automotive applications, fragrances,pastry gels, eyebrow dye, paints, hair paints, finger nail repair kit,animal medicine dispenser, animal food dispenser, culture media samples,drug test kits, and chemical testers (e.g. date rape etc.). As anillustration, although the applicator has been described as beingutilized for mechanical uses, it can similarly be used for applyingadhesives, mastic or the like. The dispenser may also be used indiagnostic testing kits, explosive testing kits or other test kits.

While the invention has been described in its preferred embodiments, itis to be understood that the words which have been used are words ofdescription rather than limitation and that changes may be made withinthe purview of the appended claims without departing from the true scopeand spirit of the invention in its broader aspects.

What is claimed is:
 1. A dispenser for dispensing a flowable material,the dispenser comprising: a container having an outer wall and amembrane collectively defining a first chamber configured to contain aflowable material, the membrane extending from the outer wall at anangle, the membrane having a thickness and a weld seam, the weld seamhaving a thickness less than the thickness of the membrane.
 2. Thedispenser of claim 1 wherein the membrane is generally conically-shaped.3. The dispenser of claim 1 wherein the membrane has a peripheral edgeand an apex spaced from the peripheral edge.
 4. The dispenser of claim 3wherein the peripheral edge is integral with the outer wall.
 5. Thedispenser of claim 1 wherein the angle is in the range fromapproximately 19° to 25°.
 6. The dispenser of claim 1 wherein the angleis in the range from approximately 20 to 22.5°.
 7. The dispenser ofclaim 1 wherein the angle is approximately 22.5°.
 8. The dispenser ofclaim 1 wherein the weld seam has a thickness in the range ofapproximately 0.003 inches to 0.004 inches.
 9. The dispenser of claim 1wherein the weld seam has a thickness of approximately 0.0035 inches.10. The dispenser of claim 1 wherein the weld seam has a thickness ofapproximately 0.006 inches.
 11. The dispenser of claim 1 wherein themembrane is non-planar.
 12. The dispenser of claim 1 wherein the weldseam forms a cross-shape in the membrane.
 13. The dispenser of claim 1wherein the membrane converges to an apex.
 14. The dispenser of claim 13wherein the weld seam comprises a plurality of weld seams, each weldseam converging to the apex.
 15. The dispenser of claim 1 wherein theouter wall has a first extension member thereon proximate the membrane.16. The dispenser of claim 15 wherein the outer wall has a secondextension member thereon proximate the membrane and generally oppositethe first extension member.
 17. The dispenser of claim 16 wherein theextension members comprise a plurality of ridges.
 18. This dispenser ofclaim 1 wherein the membrane is positioned within the container todefine a first chamber and a second chamber.
 19. The dispenser of claim18 wherein the second chamber receives a dispensing member.
 20. Thedispenser of claim 1 wherein the weld seam extends from proximate acenter of the membrane towards a peripheral edge of the membrane andspaced from the peripheral edge.
 21. The dispenser of claim 1 whereinthe membrane is positioned at an end of the container.
 22. The dispenserof claim 21 wherein one side of the membrane is exposed to an outsideenvironment.
 23. The dispenser of claim 1 wherein force applied to themembrane causes the weld seam to fracture wherein the flowable substanceadapted to be contained in the container is adapted to be dispensed fromthe container.
 24. The dispenser of claim 23 wherein after the weld seamis fractured, the membrane returns to a substantially closed positionwhen force is, removed from the container wherein the flowable substancedoes not pass by the membrane.
 25. The membrane of claim 1 wherein themembrane has a plurality of weld seams.
 26. The membrane of claim 24wherein the membrane has an apex, the plurality of weld seams extendradially from the apex.
 27. The dispenser of claim 1 wherein a firstsegment of injected molded material abuts a second segment of injectedmolded material to form the weld seam.
 28. The dispenser of claim 1wherein no material is removed from the membrane to form the weld seam.29. The dispenser of claim 1 wherein the membrane is formed while theweld seam is formed.
 30. The dispenser of claim 1 formed by aninjection-molding process.
 31. The dispenser of claim 30 wherein thedispenser is formed of a blend of polypropylene and thermoplastic olefinelastomer.
 32. The dispenser of claim 30 wherein the dispenser is formedof a blend of polyethylene and polypropylene.
 33. The dispenser of claim30 wherein the dispenser is formed of nylon.
 34. The dispenser of claim1 further comprising a second container configured to hold a secondflowable substance, the second container having a second membrane havinga second weld seam, wherein the container is contained within the secondcontainer, wherein the container is rupturable along the weld seam byforce applied proximate the membrane of the container through the secondcontainer, wherein the flowable substance is adapted to mix with thesecond flowable substance to form a mixture to be selectively dispensedfrom the second container.
 35. A one-piece dispenser for dispensing aflowable material, the dispenser comprising: a container having an outerwall and a membrane collectively defining a first chamber configured tocontain a flowable material, wherein the membrane is generallyconically-shaped, the conically-shaped membrane extending from the outerwall, the membrane having a thickness and a weld seam, the weld seamhaving a thickness less than the thickness of the membrane, wherein thecontainer and membrane are integral with one another.
 36. The dispenserof claim 35 wherein the membrane has a peripheral edge and an apexspaced, from the peripheral edge.
 37. The dispenser of claim 35 whereinan angle between the membrane and a vertical axis is approximately22.5°.
 38. The dispenser of claim 35 wherein the weld seam has athickness of approximately 0.0035 inches.
 39. The dispenser of claim 35wherein the weld seam has a thickness of approximately 0.006 inches 40.The dispenser of claim 35 wherein the membrane has an apex and the weldseam comprises a plurality of weld seams extending from the apex. 41.The dispenser of claim 35 wherein the membrane is positioned at an endof the container.
 42. The dispenser of claim 35 wherein the outer wallhas a first extension thereon proximate the membrane.
 43. The dispenserof claim 42 wherein the outer wall has a second extension member thereonproximate the membrane and generally opposite the first extensionmember.
 44. A one-piece injection molded dispenser, the dispensercomprising: a container having an outer wall and a membrane extendingfrom the outer wall at an angle from the outer wall wherein the membraneis conically-shaped, the membrane positioned within the container todefine a first chamber and a second chamber in the container, the firstchamber containing a flowable material, the membrane being formed by aplurality of segments of injected molded material wherein adjacentsegments abut one another to form respective weld seams, each weld seamhaving a thickness less than the thicknesses of the segments, the secondchamber receiving a swab in an interference fit, wherein upon forceapplied to the outer wall proximate the membrane, the membrane fractureswherein the flowable material passes through the membrane into thesecond chamber wherein the swab absorbs the flowable material to befurther dispensed from the swab.
 45. A one-piece injection moldeddispenser, the dispenser comprising: a container having an outer walland a membrane defining a chamber configured to contain a flowablematerial, the membrane extending from the outer wall at an angle fromthe outer wall wherein the membrane is conically-shaped, the membranebeing formed by a plurality of segments of injected molded materialwherein adjacent segments abut one another to form respective weldseams, each weld seam having a thickness less than the thicknesses ofthe segments, wherein the membrane is positioned at a distal end of thecontainer wherein one side of the membrane is exposed to an outsideenvironment, wherein upon force applied to the outer wall proximate themembrane, the membrane fractures wherein the flowable material passesthrough the membrane.
 46. A dispenser for dispensing a flowablematerial, the dispenser comprising: a container having an outer wall anda membrane collectively defining a first chamber configured to containea flowable material, the membrane extending from the outer wall at anangle, the membrane having a thickness and a weld seam, the weld seamhaving a thickness less than the thickness of the membrane, whereinforce applied to the membrane causes the weld seam to fracture whereinthe flowable substance configured to be contained in the container isconfigured to be dispensed from the container, and wherein after theweld seam is fractured, the membrane returns to a substantially closedposition when force is removed from the container wherein the flowablesubstance does not pass by the membrane.
 47. A method of forming adispenser for dispensing flowable materials from the dispenser, themethod comprising the steps of: providing a mold having a mold cavity tocorrespond to the exterior surface of the dispenser and a first corepoint having a length and a second core pin having a length, the corepins corresponding to the interior surface of the dispenser, the firstcore pin having a conically-shaped end face with a raised structurethereon, and the second core pin having a recessed end face; insertingthe first core pin and raised structure into the mold cavity wherein afirst space is maintained between the mold and the length of the firstcore pin; inserting the second core pin into the mold cavity wherein asecond space is maintained between the mold and the length of the secondcore pin, wherein the first core pin end face is received by therecessed end face and such that the first core pin end face confronts inspaced relation, the second core pin end face to define a membrane spacewherein the raised structure is spaced from the second core pin end faceto define an interface area; injecting a thermoplastic material into themold wherein the material flows into the first space, second space andmembrane space wherein the material flowing into the membrane spaceflows on opposite sides of the raise structure and abuts substantiallyat the interface area to define a weld seam; and removing the first andsecond core pins and removing the molded dispenser from the mold.